TBR Strategies Training Courses

TBR Strategies offers a broad range of training courses that are customized to fit your organization’s needs. These courses are all designed to help you to achieve optimal asset performance. Ultimately, our approach is to keep a laser focus on guiding each business through process development. We do this by charting the best course to integrate asset management into the very fabric of your organization. In so doing, we enable people, processes, and technology to operate in a more holistic fashion in order to make the business more competitive while achieving operational excellence.

Browse our current training courses below for more information. When you see a training or workshop you are interest in receiving more information about, please contact us.

Total Process Reliability

Total Process Reliability/TPR (3 days)

Total Process Reliability (TPR) is the next generation total productive maintenance (TPM). This evolution can be seen in its use of more contemporary tools. Among these tools are Lean Manufacturing concepts, Six Sigma elements, Theory of Constraints and Breakthrough Strategy. Consequently, TPR moves its effectiveness far beyond the limited focus of TPM on equipment uptime and availability. As a result, greater benefits can be seen in situations where equipment needs were non-existent or improvements were not cost-justified. Ultimately, TPR is a process to improve equipment efficiency by enrolling the entire organization in asset management. This is far superior to a traditional maintenance approach where the maintenance department or service personnel shoulder the entire burden.

Coordinator & Change Agent

TPR Coordinator/Facilitator Workshops

This is a rigorous, hands-on, one-week course for change agents to drive and support the TPR/TPM process. Participants are provided with tools and techniques along with extensive training in TPR processes, how to conduct training, instructional methods, change management, facilitation techniques, and problem solving.

Duration: 5 days

Change Agent Class

This advanced class is for TPR Coordinators who have been facilitating more than 3 years. It includes training in Toyota’s A3, FMEA, Histograms, Scatter Diagrams, Run Charts, Control Charts, 6M, Handling Resistance to Change, Internal Consulting, Winning Support, and Influence & Persuasion.

Duration: 5 days

PM & PdM

Introduction to Predictive Maintenance (PDM)

Introduction to various PDM and CBM technologies to include vibration analysis, infrared technologies, oil analysis, wear particle analysis, shock pulse analysis, electric surge comparison, ultrasound, contamination analysis, coolant analysis and performance trending. This includes application, costs for equipment as well as pros and cons. The course also includes the development of Predictive Maintenance Technology Matrix for all identified equipment and cost avoidance methods for justification.

Duration: 6 hours

Plant Maintenance

This program covers establishing a taxonomy or equipment hierarchy (parent/child relationship of equipment and subcomponents) in a plant, organizing a PM program for Type 1 and Type 2 activities, setting up a PdM Technology Matrix.

Duration: 8 hours

Preventive Maintenance Development Workshops

Combining research, historical data, OEM recommendations, tribal knowledge and combined experiences, participants can develop robust PMs. Using a structured format, PMs are developed that can be applied immediately to selected equipment. Practice PMs are developed in class.

Duration: 8 hours

Optimizing your PM Program

This training educates on how to fully optimize your preventive maintenance program through the elimination of low-value tasks, review of PM-related failures, replacing intrusive PM tasks, clearly developing Type 1 and Type 2 PM tasks, and reviewing PMs to improve them.

Duration: 3 hours

Early Equipment Management

Early Equipment Management (EEM)

EEM is a method used to design/specify equipment from inception to completion in the shortest amount of time. Hence, this course covers optimizing life cycle costs and maintenance-prevention design. Additionally, it also covers the four areas of life cycle cost: Maintenance, Design, Development, and Operation as well as their specific contributions and interaction with each other. Participants will learn Life Cycle Cost Analysis (LCCA)/Life Cycle Management (LCM) concepts such as alternate financing options, various acquisition methods, and different equipment comparison. Other aspects include improving replacement decision making, accessibility and maintainability designing as well as hourly operating costs.

Duration: 8 hours

Leadership

Leadership Training

A 50 to 60-hour course on leadership given in 2 to 4 hour modules. This 17-module training program promotes excellence through the learning and use of practical leadership skills, abilities and strategies valuable for their change and innovation guidance. The courses provide principles and essentials of contemporary leadership, goal setting, and essential human resource and communication skills. Modules include:

  1. Who and Why of Leadership
  2. Leadership Fundamentals
  3. Rewards and Positive Reinforcement
  4. Improving Performance through Coaching
  5. Seeking and Gaining Good Information
  6. Effectively Selling Ideas
  7. Leading and Managing Change
  8. Setting Clear Performance Expectations
  9. Decision Making
  10. Identifying and Developing Job Skills
  11. Taking Corrective Actions on Performance
  12. Setting Clear Roles for Teams
  13. Resolving Conflicts in Teams
  14. Effective Delegation
  15. Time Management
  16. Leading Creativity and Innovation
  17. Interviewing Skills

Duration: 50-60 hours

Team Leader Workshop

An eight-hour course on leading and facilitating team meetings including team dynamics, conflict resolution, problem solving structure and problem solving tools. Includes simulated meetings with a variety of challenges while applying problem solving to situations. Various methods/tools for effective problem solving using the DMAIC Model. Learn brainstorming techniques, Pareto Charts, Process Flow Diagrams, Cause & Effect Diagrams, Force Field Analyses, and other tools and techniques.

Duration: 8 hours

Auditing

Auditing

This course trains participants in implementing the crucial governance area of TPR Auditing. Topics covered are: Key reasons for leadership auditing, why we audit, auditing process, what to audit, how to audit, rules of auditing, best practices of auditing, key performance indicators, the Three C’s of Auditing, audit evidence, auditor tips, how to use the results, auditing your audits, key factors in auditing success, and examples of audits. The training program is concluded with a hands-on audit on a real piece of equipment with the equipment standards and an audit checklist.

Duration:  4 hours

Refresher Auditing Training

This 2.5-hour class is a review of auditing practices and then hands-on practice where we plant faults or defects in equipment for auditors to find.

Duration: 2.5 hours

Operator Care-TPM

Operator Care

This program establishes a methodology to achieve “Best in Class” distinction in the establishment of an Operator Care program. Covers task standardization, clarification of expectations, lubrication basics, cleaning methods and importance, inspection techniques and simple repairs. A Seven Step Model is used.

Duration: 4 to 5 hours

5S Workshops

A way to bring more orderliness and organization into the workplace, these five-day hands-on workshops teach participants the Japanese concept of 5S: Sort, Set in Order, Shine, Standardize and Sustain. An excellent starting point for all improvement programs because it helps to create a stable environment that shows visible change occurring.

Duration: 5 days

Proxy Tech Program

A training program for identifying and training an operations person to be designated proxy tech or mechanic for each crew from testing, selection, tasks, identification, using RACI for tasks, resource/tool identification, that will supplement operator CLAIRE tasks.

Duration: 4 hours

CMMS Selection Training

We offer CMMS Selection training to guide organizations to choose and adopt the right CMMS to fit your company’s needs and culture. Participants are educated on the purpose of a CMMS, major elements and modules of CMMS, CMMS/EAM/ERP, process of selecting a CMMS, CMMS barriers, CMMS issues, and requirements for success with CMMS. A 100-item World-Class CMMS capabilities checklist is distributed showing what a World Class CMMS should be able to perform. Those taking the course will learn how to: set User Requirements, set up a decision matrix, develop an RFI, evaluate various alternatives, and basic implementation.

Duration: 4 hours

EIT / CLAIRE Workshops

Equipment Improvement Teams (EITs) are four-day or five-day hands-on workshops where operators and mechanics learn better ways to operate and service their equipment. This is accomplished through CLAIRE (Cleaning, Lubricating, Adjusting, Inspecting, Repairing, and Eliminating). The course also covers teaming, development of standards, creation or refinement of Preventative Maintenance procedures (PMs), equipment upkeep, TPR communications, and restoration to an “as designed” condition.

Duration: 4 or 5 days

RCA & RCFA

RCA Training

Participants learn to apply an effective 6-step method to determining the root causes to issues and how to apply a Corrective Action Plan (CAP). 5-Why and other techniques are covered.

Duration: 4 hours

RCFA Training

An 8-hour program providing valuable concepts, principles, and techniques used to identify causal factors for equipment failure. Using Cause Mapping, they learn to: investigate contributing causes and determine the root cause; develop, assess, report, and implement appropriate countermeasures and corrective actions. The goal is to learn the process used to determine the real reason for a failure or event and direct solutions to prevent the problem from returning.

Duration: 8 hours

Toyota’s Kaizen A3 Improvement Process

Several of our clients like Area Energy use this for process improvement. One of our new consultants, Lisa Wayne, came from Area Energy after 18 years there, and has extensive experience facilitating and training in this process.

Duration: 4 hours

Technical

Fasteners Training

This 2-hour technical training includes: bolt terms, fasteners-how to read them, what replacement fastener to use, fastener categories, fastener head styles, bolt or tensile strength, torqueing, fastener grades, hex wrench or hex nut, using the right tool for the job, how to remove a stuck fastener, stud removal, when to use a new fastener, thread inserts, and nuts.

Duration: 2 hours

Fundamentals of AC and DC

The course starts with basic terms and applications of Static, DC, and AC electricity. Furthermore, participants study Voltage, Current, Resistance and Power in production applications. Other aspects include Review of Ohms Law as well as power vs control in electrical circuits used throughout industry.

Duration: 4 hours

Lubrication Basics

This course covers various forms of lubrication, purpose of lubrication, and viscosity. Students learn about the viscosity grade of grease, classic problems with over lubrications and wrong types, typing lubes by speeds, loads, and temperatures. Additional aspects include learning proper storage methods, use of greasing standards, various methods of delivery, how to calibrate grease guns, proper grease gun storage, and additives.

Duration: 2 hours

Tools & Techniques

Management of Change (MOC)

Change management is all about the process of implementing change of a system in a controlled manner by following a pre-defined framework or structure. We help to establish a MOC process to control change and minimize the impact of poorly planned and executed change.

Duration: 8 hours

Process Mapping (Process Flow Diagramming)

Our trained facilitators facilitate activities to flow chart existing and desired processes. Process Maps or Process Flow Diagrams are logical step-by-step representations of business activities showing key inputs/outputs. It is a graphic depiction of the sequence of events or tasks.

Duration: 4 hours

RACI Chart Training

RACI (Responsible, Accountable, Consult, and Inform) charts are a valuable tool for organizations to improve the understanding of roles and responsibilities for an assigned task. Topics include: Setting clear performance expectations, general guidelines of making a RACI chart, RACI steps, analyzing RACI charts, and an exercise in developing a RACI chart.

Duration: 4 hours

Training & Development

Train-the-Trainer Workshop

This workshop provides participants with the knowledge and ability to successfully conduct training sessions. It also provides hands-on training in learning styles, adult learning principles, training aids, Single Point Lesson Plans, basic facilitation skills, Structured OJT, and effective handling of problem situations. Participants practice these concepts in staged scenarios, and by the end of the course, conduct a training session.

Duration: 8 hours

Job Aid Development Training

Training in the development of devices and tools (instruction cards, Single Point Lessons, memory joggers, wall charts, etc.) that allows individuals to quickly access information to perform a task and rely less on recall.

Duration: 4 hours

Job Task Analysis

By examining the tasks or activities necessary to perform that job as well as the necessary tools and skills, participants learn the process of analyzing how a job is accomplished. The process often includes: task lists, job breakdowns, performance standards, skills & knowledge, and tools & equipment. The main objective is to determine training needs, but it can be applied to development of job descriptions, promotional criteria, etc.

Duration: 2 hours

World Class Certification Training

A 3-hour course that paves the road to World Class training. We cover characteristics of world class training, ADDIE training model, certification program, re-certification, training tools, and resources.

Duration: 3 hours

Planning & Scheduling

Planning & Scheduling Management Overview

This 3-hour program provides an overview to supervisors and managers as to the value and means of how to support maintenance planning and scheduling processes. Participants learn about symptoms of a broken planning process, benefits of good planning and scheduling, savings and contributions to the bottom line, roles, responsibilities, duties of a planner, maintenance reporting, net capacity, and backlog.

Duration: 3 hours

Planning & Scheduling

This is a 2 or 3-day workshop that covers the core concepts involved with this crucial maintenance process. The training program delves into the everyday role and responsibilities for Planning and Scheduling. Day 1 teaches why P&S is beneficial, what is planning, what is scheduling, the duties of each, and how P&S affects wrench time. Day 2 involves planning, explaining the identification of work requests, work orders, kitting, and prioritizing work. Planning work with site visits and creating Job Plans is examined. Day 3 covers proposing, approving, publicizing, and managing the backlog of the schedule. Training on executing the schedule and closing out the schedule. The importance of receiving feedback to implement improvements and revisions is also included. Numerous written and hands-on exercises are utilized. A condensed 2-day version is available.

Duration: 2 or 3 days

OEE & Equipment Optimization

Overall Equipment Effectiveness Training (OEE)

OEE training is an overview of maximizing the performance of equipment by minimizing losses of equipment and solving the problems by teams. We discuss the steps of improvement with OEE by: Defining losses, quantifying losses, analyzing losses, generating counter-measures, implementation, and following up. An exercise is performed in how to calculate OEE.

Duration: 4 hours

Equipment Utilization & Optimization Training

How can we manage our equipment cost better? We answer this question and more by covering: Equipment optimization challenges, steps for equipment optimization, definition and purpose of optimization and utilization as well as ROCE, and RONA. Other aspects include establishing a plan to ‘right size’ the fleet, optimizing fleet assets, disposal consideration, examining utilization, looking at repair costs, life cycle costs, life cycle analysis, life cycle management, the 5 life cycle phases. In addition, we cover how to increase utilization, getting the highest residual value, reducing operating costs, lowering PM costs, using standards and auditing, and reducing CM costs.

Duration: 4 hours

Inventory Control

Introduction to Inventory Control

A 4-hour training session that introduces inventory control/management. We examine why inventory costs are so high and the realities of not controlling our inventory. Other topics include: Reasons for inventory control, carrying costs, supply and demand, how to begin your control, maximum inventory, minimum inventory, ABC classification, Pareto’s Law (80/20), cycle counting, how to cycle count, and EOQ (Economic Order Quantity). Other aspects include: calculating EOQ, balancing carrying vs. ordering costs, factors of a successful inventory control system, visual controls, and examples of successful inventory management.

Duration: 4 hours

Contractor / Vendor Management

A workshop dedicated to reviewing the process of deciding if and when to use outside sources for labor or materials; and how to enhance the relationship so it is mutually beneficial. In addition, learn to: select, manage, and evaluate contractors/vendors. Also, how to properly deal with problems if they arise.

Duration: 4 hours

Maintenance, Repair & Operations-Inventory Control (MRO)

MRO is a 3-day course which goes in full detail of Maintenance, Repair, and Operating inventory management.

Day 1 consists of: types of inventory, storerooms, inventory management, parts criticality, VED (Vital, Essential, Desirable) approach, examining alternative stocking, storeroom activities, storeroom layouts, stocking basics, enforcing security, storeroom procedures, examples of World Class storerooms, parts numbering, intelligent numbers, storeroom accuracy, carrying cost case study, repetitive items, critical spare types, maintaining an accurate inventory, best practices, and storeroom challenges.

Day 2 includes: Stockroom basics exercise, effective inventory management, relevant inventory costs, carrying costs, reorder points, safety stock, service level, ABC analysis, an ABC analysis exercise, how to cycle count, EOQ (Economic Order Quantity), stock control, return for credit control, visual controls, inventory turnover, and inventory accuracy.

Day 3 concludes with: the supply chain, role of purchasing, supply chain management, cost of a PO (Purchase Order), the four standards of buyers, unethical behavior, Kraljic supply Matrix, purchasing cycle, purchasing inputs/outputs, supplier/vendor management, RFP (Request for Proposal), vendor review exercise, policies and procedures, RACI charts, steps for procedures, and deployment model. Numerous videos and exercises are used to further engage the trainee.

Duration: 3 days

Failure Mode Effects Analysis

Failure Mode Effects Analysis (FMEA)

This 4 or 8-hour training covers reducing risk and reliability. Topics explored are: What is FMEA, evolution of maintenance practices, FMEA history, what FMEA will do for you, Failure Mode Effects and Criticality Analysis (FMECA), cost comparisons, facts about PM, Inspections, why FMEA/FMECA is important, how to use an FMEA, various forms of FMEA, important definitions of FMEA, occurrence, severity, detection, Risk Priority Number (RPN), various examples of FMEA, FMEA process, FMEA checklist, FMEA tools, FMEA tips, why some FMEA’s fail, and risk analysis. There are 2 exercises in this module to set FMEA ratings and do an actual FMEA.

Duration: 8 hours

Accelerated Failure Modes and Affects Analysis (AFMEA)

Accelerated FMEA is a means to identify failure modes, their causes, and effects. It uses a numerical value to rate the risk for problematic components to help identify strategies to either mitigate or detect to reduce failure rates. This process is used extensively by NASA, Dept. of Defense, automotive manufacturing, aviation and high tech manufacturing to reduce failure rates. Accelerated FMEA was developed by TBR Strategies to expedite a normally long and labor intensive process and can reduce the FMEA development time.

Other Services

Maintenance Effectiveness Assessment (MEA)

An objective and comprehensive analysis of your maintenance systems, strengths and weaknesses. Takes from one to three weeks on-site. Examines maintenance practices, culture, support resource availability, operator care, skill levels, and readiness of the organization to support and sustain a maintenance improvement effort. Comparisons are made to recommended practices, industry averages, Best in Class, and World Class benchmarks and a gap analysis is developed. Client Progress Assessment (CPA)-An extensive maintenance and reliability systems analysis. The (CPA) is a 450-point analysis that identifies specific gaps based on industry best practices.

Department/Division Strategic Planning

We can facilitate a retreat to develop an organizations strategic plan using Harvard’s Balanced Scorecard (BSC) approach used by over 50% large US firms. This includes the development or refinement of a vision, mission, goals, core principles, key performance indicators, initiatives for implementation, and an implementation plan. A unique planning process used to develop a comprehensive action plan and tactical implementation steps. Individual steps are listed, resources identified and dates agreed upon. Pilot areas are also selected. Balanced Scorecards guide the strategy and a Dashboard to track progress. A process for communicating changes is also developed. Part of this step also includes setting up benchmark visits to study exemplary performance at other locations.

Duration: 3 days

TBR Strategies, LLC

TBR stands for Team-Based Reliability, an approach that engages the people in your organization in improving reliability and maintenance of your equipment.

TBR Strategies, LLC is able to achieve desired results by getting your employees to work together toward a common goal...fleet uptime. TBR has extensive experience in construction fleets, pharmaceutical, chemical, and oil and gas production.

Location

7000 Harps Mill Rd, Suite 202
Raleigh, North Carolina 27615

Phone

919.341.1387

Fax

919.847.3102